Removing Engine

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapours.
- Attach warning sign in a clearly visible position.
- Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
- Secure collection containers/vessels to prevent them from tipping over.

WARNING: Caustic fluids

Danger of chemical burns
- Wear personal protective gear.
- Ensure that there is good ventilation.
- Avoid contact with caustic fluid.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

NOTIFICATION

Aggressive fluids

Risk of damage to components and surfaces
- Do not spill fluids.
- In the event of contact, wash the component or surface with water.
- Replace components that are already damaged.

Information

The slightly different illustrations between V8 and V6 show essentially the same actions.

Information

When lowering the engine, make sure that no cables, hoses or lines are fitted between the engine and body.
Get a second person to help you check this.

Release electric plug connection -1- M - on the DME control unit -2- (-a-) and pull it off -A- .

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Plug connection on DME control unit
Loosen fastening nut -1- for ground point at the body and remove ground cable -2- to the DME control unit.
Cut the tie-wrap if necessary.

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Ground point on body
Remove the tie-wrap -3- if necessary.
Open the cover of the front relay box in the plenum panel.
> WM 970955 REPLACING SUB-PART OF WIRE HARNESS IN ENGINE COMPARTMENT AT THE LEFT
Release and unplug the electric plug connections -1- on the engine wire harness.

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Disconnecting plug connections
Unclip the engine wire harness -1- in the plenum panel from the retaining clips -2- and remove it.

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Engine wire harness in plenum panel
Remove B+ transfer point on the left spring dome. To do this, loosen the two positive cables at the pins. Clip in cable on the bulkhead. Lay the cables for the engine.-A and B-

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B+ transfer point on left spring dome

Disconnect the two coolant lines and the vacuum line on the right side of the engine compartment. -1 to 3- Simply pull off the vacuum line (hold line securely below the connection).

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Wiring

Disconnect the coolant line -1- from the coolant reservoir -2- at the bleeder valve.

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Coolant lines at the reservoir

Loosen the clamp -3- on the coolant hose -4- at the coolant reservoir -2- .
Pull off the coolant hose.

Disconnect the four oxygen sensor connectors on the body next to the spring-strut dome on the right and unclip the cables from the holders. -l, 2, 3 and 4- Set down the cables for the engine.

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Oxygen sensor connector next to spring-strut dome
Drain the hydraulic fluid reservoir -1- and the PDCC reservoir -2- , if necessary, using a suitable tool.
Then remove the hoses -3, 4- at the reservoirs and close them off using suitable stoppers.

> WM 489719 REMOVING AND INSTALLING RESERVOIR (EXCEPT CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

> WM 430955 REPLACING RESERVOIR (PDCC) (CAYENNE, CAYENNE GTS, CAYENNE TURBO S, CAYENNE S, CAYENNE S E-HYBRID, CAYENNE TURBO, CAYENNE S DIESEL, CAYENNE (3.0))

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Hoses for hydraulic reservoir
Disconnect fuel line -1- at the transfer point (counter!). Unclip the fuel line at the plenum panel.

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Plenum panel lines
Release clamped connection -2- on the tank ventilation line.
Disconnect the coolant supply and return lines from the radiator. To do this, pull out the securing clip at the upper hose and pull off the connection -1- . The clip should be fitted again immediately to avoid confusion. Undo bottom hose -2- . To do this, undo spring band clamp and pull off hose.
Disconnect the small breather hose from the connection piece. To do this, loosen the spring band clamp.

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Coolant hoses
Raise the vehicle.
Disconnect the ground point on the right longitudinal member. -arrow-

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Ground point on right longitudinal member
Unscrew fastening screws -1, 2- for holders -3, 4- for brake hydraulic lines.

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Holders for hydraulic lines
Loosen holders from the wheel bearing housing -5- .
Release electric plug connections -1- for the speed sensor on the wheel bearing housing -a- and pull them off -A- .

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Plug connections on wheel bearing housing (shown as an example)
Remove the brake calliper and suspend it at a suitable position in the wheel arch > Suspending brake calliper (do not open brake hydraulics!).
Also protect the brake calliper (e.g. with a cloth or suitable rubber mat) to prevent damage to the paintwork.

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Suspending brake calliper
Remove fastening screws -1- for the connecting links -2- at the bottom of the anti-roll bar -3- .

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Connecting link for anti-roll bar
Press out the ball joint between the wheel carrier and upper wishbone using > T10187 - ball joint puller.
Unscrew the fastening screw -2- for the spring strut -3- and at the same time, raise the axle support -1- as far as required using a suitable jack -4- so that the fastening screw can be pushed out easily.

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Removing spring strut mounting
Loosen the fastening screw -1- on the holder -2- for ATF lines -3- at the thermostat -4- .

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ATF lines from thermostat to transmission
Place a suitable container underneath to catch emerging ATF.
- Place a suitable panel under the thermostat and allow emerging ATF to flow from the body.
- Pull ATF lines out of the thermostat.
- Close off the ATF lines and bores on the thermostat using suitable stoppers.
Loosen the clamping screw -1- on the steering column -2- at the steering gear -3- .

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Loosening steering column at the steering gear

Slide the steering column -2- upwards -arrow- and pull it down off the steering gear -3- (-A-) .
Pull clamps -1- off the coolant lines -2- for the heating water heat exchanger in the engine compartment at the rear left on the wheel housing.

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Coolant lines in front left wheel housing
Pull off coolant hoses -2- .
Loosen the cardan shaft at the transfer gear using a mounting lever and tie it up.
> WM 390219 REMOVING AND INSTALLING FRONT CARDAN SHAFT (ALL MODELS)
Detach heat shield on the right of the transmission. To do this, unscrew three fastening screws -arrows- .

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Heat shield
Release electric plug connections -1, 2- at the right of the transfer gear -a, b- and pull them off -A, B- .

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Plug connections for transfer gear at the right
Release electric plug connections -1, 2- at the bottom of the transfer gear -a, b- and pull them off -A, B- .

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Plug connections for transfer gear at the bottom
Mark gearshift position - N - -1- on the automatic transmission -2- with a suitable pen -A- .

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Marking gearshift position
Remove shift cable -3- on the automatic transmission -4- .
> WM 371519 REMOVING AND INSTALLING SELECTOR LEVER CABLE (ALL MODELS)

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1. Unclip the cable -3- at the front on the ball joint -1- using > VAS 6933 - Disassembly tool.
2. Unscrew fastening screws -2- at the rear shift cable -3- .
Loosen the clamp -1- on the hydraulic line -2- in the front left wheel housing and pull the hose off the hydraulic line.

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Close off the line and connection piece using suitable stoppers.
Loosen the fastening screw -1- for the refrigerant line -2- at the front left longitudinal member -3- and pull out the line.

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Front left refrigerant line
Remove the line -1- from the air-conditioning compressor to the condenser -2- .

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Line from air-conditioning compressor to condenser
1. To do this, unscrew the fastening screw -3- for the line -1- at the condenser -2- .
2. Close off lines and connection pieces.
Loosen fastening nuts -8- on the exhaust clamp (clamping sleeve) -3- between the catalytic converter and exhaust system. Slide exhaust clamps onto the exhaust system. The exhaust clamps must not be re-used.
> WM 260119 REMOVING AND INSTALLING EXHAUST SYSTEM (CAYENNE TURBO, CAYENNE TIP, CAYENNE S, CAYENNE TURBO S, CAYENNE S DIESEL, CAYENNE TURBO S & CAYENNE TIP "PLATINUM EDITION")

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Loosening clamps
Mark the installation position of the front-axle carrier diagonally on at least two places on the body using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body during reinstallation.

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Marking installation position of front-axle carrier

Information
- Because of the high loosening torque, the six fastening screws on the front-axle carrier can already be loosened now. Loosen the screws by a maximum of one turn.
Place the lifting platform under the engine and raise it. When you do this, ensure that the positioning guides of the lifting platform are inserted into the body. > Lifting platform under engine

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Lifting platform under engine
The -arrows- show the mounting points for the mounting frame in the front-axle carrier (view from below here).

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Mounting points for front-axle carrier
Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)-, -4 into the body- .

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Lifting platform
Secure the spring struts. To do this, turn the rubber discs upwards until they are set under the steering knuckle. Then tighten the retaining brackets on the wheel hub and lifting platform. -arrow-

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Securing spring struts
Loosen the transmission cross member. To do this, loosen the four fastening screws -A- .

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Fastening screws for transmission cross member
Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the engine transverse bar. > Fastening screws on front-axle carrier and fastening screws on engine transverse bar (center)

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Fastening screws on front-axle carrier and fastening screws on engine transverse bar (center)
Lower the lifting platform slowly by approx. 20 to 30 cm. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and spring struts in the wheel housings.
Information

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Adhesive tape markings on the workshop floor
- Before moving the unit elevating platform, mark the position of the wheels on the workshop floor with adhesive tape. This makes it easier to position the platform again for re-installation.
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Position of lifting platform
Lower the lifting platform fully. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.